Method of producing contour molded cotton batting



Oct. 31, 1967 B. KNOEPFLER ETAL 3,3 0, 3

METHOD OF PRODUCING CONTOUR MOLDED COTTON BATTING Filed April 29, 1965 4 Sheets-Sheet l INVENTORS NESTOR B. NOEPFLER ET AL BY Kl ATTORNEYS -3 1967 N. B. KNOEPFLER ETAL 3,350,486

METHOD OF PRODUCING CONTOUR MOLDED COTTON BATT ING Filed April 29, 1965 4 Sheets-Sheet 2 INVENTORS NESTOR B. KNOEPFLER ET AL ATTORNEYS ING O 3 1967 N. B. KNOEPFLER ETAL METHOD OF PRODUCING CONTOUR MOLDED COTTON BATT 4 Sheetsheet 3 Filed April 29, 1965 I 1 1w r 1/ a FlGA-B FIG.4A

FIG .4c

INVENTORS NESTOR B K Oct. 31, 1967 N. B. KNOEPFLER ETAL 3,3

METHOD OF PRODUCING CONTOUR MOLDED COTTON BATTING 4 Sheets-Sheet '4 Filed April 29, 1965 FIG/5A FIG. 6

INVENTORS I B. NOEPFLER ET AL NESTO ATTORNEYS United States Patent Ofitice 3,350,486 METHOD OF PRODUCING CONTOUR MOLDED COTTON BATTING Nestor B. Knoepfler, New Orleans, and Homer K. Gardner, Jr., and Henry L. E. Vix, Metairie, La., assignors to the United States of America as represented by the Secretary of Agriculture Filed Apr. 29, 1965, Ser. No. 452,032

11 Claims. (Cl. 264-112) sublicenses for such purposes, is hereby granted to the States of America.

This is a continuation-impart of Ser. No. 271,525, which was filed Apr. 8, 1963 and which has now matured 1nto Patent No. 3,181,225, granted May 4, 1965. The in- We have unexpectedly found that by modifying the process of said Patent No. 3,181,225, we can (I) produce a batt which has a permanently-contoured shape, (2) produce a batt which has preselected and desired varying degrees of compaction, either in the same or in separate batts, and (3) produce a batt which has the combined desirable qualities of permanently-contoured shape and permanently-compacted homologous or varying configuration.

To obtain the most desirable batts with contoured configuration and/ or varying degrees of compaction, We can submit the cellulosic batting material to the resinous spray treatment of said Patent No. 3,181,225; and when the spray damp wet add-on is about from 50% to 150%,

and the resiliency, etc. However, while the material produced by process of said Patent No. 3,181,225 is generally of a homogenous and regular fiat configuration, the material produced by the process of this continuation-inpart can have a curved configuration, a varying degree of compactness, or a combination of these. For producing the contoured or the variably compacted batts by processes of this invention, it is essential that the degree of dampness amounts to at least 50% by Weight based on the weight of the unsprayed web.

We have found that a spray dampness under 50% will yield a batt with poor resilience and poor shape-retention. The material will not hold the predetermined configuration or degree of compaction. A spray dampness above will be are generally attributable to resin migration during drying. The preferred 100% spray dampness to be in the preferred category must be from a solids bath.

This invention relates to a process for improving fibrous cotton batt as its dimensional stability, resilience, and compaction are improved. The process consists basically of the application of chemical substances to the opened and garnetted fibers of cotton, which can consist of a blend of various grades of cotton lint and linters 3,350,486 Patented Oct. 31, 1967 to produce a superior batt with excellent variable propertles.

This invention is combat the increasing competition to cotton material by the recent advances mattresses, motive cushioning, etc.

Another object of this invention is to provide a process for making fibrous batt with improved resistance to compaction, and having better coherence than normal commercial batting.

A further object of this invention is to facilitate the applications such as insulation.

The application of the chemical substances is done through a single or a plurality of nozzles, Which wet the web as it moves past the fine spray. The spray must be fiber. A crosslinking reaction gives the cellulosic molecule a certain amount of rigidity, which in turn causes physical, as well as chemical, rigidity or resiliencyas desiredto the cotton batt.

The resins used in this process are selected for their inherent properties, which include the capability of reactwith the cellulose of the cotton. These flexing or bending.

The function of the latex, which in effect is a film forming resin, or coatin' is to assure interfiber binding at points of contact between fibers. The latex then contributes to dimensional stability, coherence, and textile tensile and tear strength of the finished batt.

ibers within the structure under varying conditions of aumidity. The application of both crosslinking resin and latex to the web will yield a batt with these characterstics plus improved resiliency.

An important feature of this invention is the means employed for the application of the chemical substances to the webs, or layers of fibers, so that a great degree of uniformity of treatment can be obtained while the operation is of a continuous economic character.

The advantages and objectives become more apparent upon a consideration of the accompanying schematic drawing in which FIGURE 1A depicts an embodiment of a conventional apparatus for carrying out the inventive processing sequence for the production of batting, including the conventional method of crosslapping and the application of an appropriate resin alone or combined with a latex by spraying;

FIGURE 1B depicts another embodiment of apparatus similar to that of FIGURE 1A, differing therefrom in the main in that it illustrates the conventional reel-type batt former;

FIGURE 2 shows a sectional view of a batt prepared by adherence to the process of this invention;

FIGURE 3 shows a cross section of a batt after spraying, and during drying, while said batt is restrained between frames spaced to regulate the density of the product;

FIGURES 4A, 4B, and 4C are views depicting the use of expanded metal for mold parts to produce a batt simulating the contour of the arm of an upholstered sofa;

FIGURES 5A, 5B, and 5C are views depicting the use of expanded metal for mold parts to produce a batt simulating the contour of an automobile bucket seat; and

FIGURE 6 is a view illustrating that in the molded product the greatest density occurs at the thinnest portions of the batt.

Referring to FIGURE 1A, blended cotton fibers consisting of textile wastes and linters in various proportions are fed to the main cylinder 1a of the carding section of a conventional garnett, worked by worker rolls 2a, stripped from the worker rolls and returned to the main cylinder by stripper rolls 3a, removed from the main cylinder by conventional doffer roll 4a, combed from the doffer roll by comb 5a which works against the doifer roll 4a and bafile 6a, and transported in web form on traveling aprons 7 and 7a for lap-forming operations. In FIGURE 1B, the apparatus depicted operates in much the same manner as that of FIGURE 1A, with the parts thereof corresponding to those of FIGURE 1A being respectively illustrated by main cylinder 1b, worker rolls 2b, stripper rolls 3b, doffer roll 4b, comb 5b, baffie 6b, and apron 7b. This embodiment differs in the main from that of FIG- URE 1A in that the web form is transported to reel 11 for lap-forming operations. The foregoing description relating to FIGURES 1A and 1B constitutes conventional commercial practice and as such is incidental to and forms no part of the instant invention.

Following removal of the web of carded cotton fibers from the main cylinder, the web is sprayed by means of spray device 8a in FIGURE 1A or 3b in FIGURE 1B, and the sprayed web 9a in FIGURE 1A or 9b in FIG- URE 1B, now wetted with the several component reagent according to the instant invention, is lapped to produce partially-formed batt 10 as shown in FIGURE 1A or collected on reel 11 as shown in FIGURE 1B.

The sprayed and layered webs are then condensed into batts through rolls or other suitable pressure means, not shown, to assure good contact between the successive layers 12 (FIGURE 2) of webs.

In FIGURES 1A and 1B, the feed material consists of a blend of 60% of first-cut linters, and 40% of various grades of textile wastes. This mixture is an example, and in no way critical to the process. The blend is passed through suitable commercially-available processing units to be formed into a web or layer of fibers, which are discharged onto a moving belt or conveyor. At this point, the fibers are in an extremely open configuration, which makes possible the application of the resins and/ or resin- Ous or other type latex by a spray system, using a single or a multiplicity of spray heads or nozzles in such a way as to achieve a uniform distribution of the chemicals on the web. The wet add-on of the solutions can be controlled to between 20 and 150% of the Weight of the fiber feed by controlling the flow of solutions to the spray heads.

In specific examples of this invention, the optimum wet add-on varied from 70 to depending on the properties desired in the finished products.

The concentration of the spray solution or suspension mixture can vary from 1 to 35% by weight total solids, depending on the resin to latex ratio, the nature of the reagents, and the properties desired in the finished product. After being sprayed, the web or layer of fibers is either crosslapped conventionally as in FIGURE 1A, and then condensed through suitable rolls or other means to assure good contact between successive layers or webs, or collected on a reel, where condensing is done on a layer for layer basis, as shown in FIGURE 1B. The formed batts are then constricted by frames 13 (FIG- URE 3) in such a manner as to maintain a specific height during drying and curing; or dried and cured without restraint, depending on the desired physical properties, such as density. Since a structure consisting of cellulosic fibers which have been formed into batts tends to expand in volume when subjected to heat or hot air circulation, this invention takes adavntage of this inherent characteristic in order to achieve a more open (less dense) finished product. The density of the product therefore can be varied by either varying the weight of the webs, the number of webs or layers of fibers used in the batt, or by varying the spacing between frames, as in FIGURE 3, or by adjusting the spacing between suitable open mesh dual belts for continuous drying.

The spray from a single solution has been accomplished by investigative formulation, which included the search for compatible systems which can contain the resin, the latex, the catalyst, the thickening agent, the dyes, and the solvents, which go into the spray application in a single solution or suspension or both.

Pretreatments of the raw stock feed, such as mercerization, scouring and wet processing with chemicals, such as formaldehyde, significantly enhance the properties of the finished product.

The many facets of tihs process, and their proper application by adjusting to the most suitable variables make it evident that there are many advantages to be gained in the practice of this invention. The following specific examples refer to materials actually produced on an experimental basis, and are in no way to be construed as specific limits to the flexibility of the system.

The batts produced by the use of this invention are dimensionally stable and resilient, and demonstrate a marked ability to reproduce contours of the confining mold used to restrain them during drying and curing.

Drying temperatures up to 325 F. can be used depending on whether drying will be carried out simultaneously with curing or as a separate unit operation to be followed by curing. In the latter instance drying temperatures up to 220 F. would be adequate for drying if followed by temperatures of up to 325 F. for curing. Suitable temperatures within this range can be selected depending upon the requirements of the chemicals employed. Evidence exists that the degree of expansion obtained in the finished product depends upon a relationship between the time of drying and the temperature employed. In general, longer times at lower temperatures will result in a more expanded structure in the finished product.

Upon the completion of the drying and curing step or steps, the product retains its preselected height, width, and length. Furthermore, the product is one having improved resilience, a resistance to deformation from compressive loading much greater than untreated cotton batting,

proved product can be demonstrated both at high and low relative humidities.

We have now discovered that it is possible to produce while spray damp, then drying and curing at the select times and temperatures which are applicable to the chemicals and conditions chosen.

The most essential is the adjustment of the spacing between the male and the female die or mold. Shape-conforming, ally stable, coherent integral units solution,

blends of wool and cotton.

Because textile wastes tion of cotton batting are on occasion these wastes normally used in the producderived from diverse sources, may contain varying nominal amounts of synthetic fibers, such as polyesters or acrylics polyethers or others either by chance or design. The pres ence of these synthetic fibers would not preclude the us of the waste in the practice of this invention.

In general, according to the invention, the method for producing a contoured and/or variably compacted fibrous cotton batt with improved stability, coherence, and resilience, comprises the following operations carried out in sequence:

(a) forming webs of opened textile fibers of the group consisting of cotton fibers, and chemically modified cotton fibers; A

(b) spraying the webs to a wet add-on about from 50% to with a resin-forming composition at least one component of which is a cellulose reactive crosslinking reagent to a resin add-on of about from 3.76% to 24.2% by weight of the cellulosic reactive component, based on the weight of the unsprayed web;

(c) placing the spray damp batt, wherein the degree of dampness amounts to at least 50% by weight, based on the weight of the unsprayed web, in a confining mold designed to impart to the finished batt a contoured configuration;

(d) drying the batt for about from 5 to 30 minutes of time at about from to 220 R; and

(e) curing the dried batt for about from 2 to 30 minutes of time at about from 300 to 320 F.

minutes of time at about from 300 to 320 F. to produce a batt with varying degree of fibrous compaction.

The above general procedure, wherein the webs are weight of vinyl acrylic polymer, illustrates one embodiment of the invention.

The above general procedure, wherein the webs are formed from opened cotton fibers and the resin forming composition comprises approximately equal parts by weight of a urea-formaldehyde resin and vinyl acetate copolymer, illustrates a second embodiment.

The said general procedure,

and Chance et al., Formaldehyde Treatment of Partially Swollen Cotton, Textile April 1961), and the resin The said general procedure, wherein the webs are formed from opened cotton fibers that have been chemically modified by the aforesaid form W formaldehyde treatnent and the resin forming composition comprises approximately equal parts, by weight, of a urea-formaldehyde and vinyl acetate copolymer, represents a fifth embodiment.

The said general procedure, wherein the webs are formed from opened cotton fibers that have been mercerized and the resin forming composition comprises approximately equal parts, by weight, of a urea-formaldehyde and vinyl acetate copolymer, represents a sixth embodiment.

The said general procedure, wherein the webs are formed from opened cotton fibers that have been mercerized and the resin forming composition comprises approximately 7 parts, by weight, of dimethylol ethyl carbamate and about 3 parts, by weight, of vinyl acetate, represents a seventh embodiment.

The said general procedure, wherein the webs are formed from mechanically opened cotton fibers and the resin forming composition comprises methylated methylol melamine, represents an eighth embodiment.

These various embodiments are set forth in greater detail in the following examples:

EXAMPLE 1 Using a rawstock feed consisting of 60% first cut linters and 40% textile waste made up of willowed picker, 10% willowed sweeps, and 20% willowed fly, a web was made using a sample card. The web was sprayed while on the apron of the card with a treating media consisting of 22.8% solids. The solids consisted of 76% by weight, of methylated methylol melamine and 24% vinyl acrylic copolymer. The wet add-on was approximately 100% by weight of the feed. The resulting product had therefore approximately 12% resin content (not including the latex), and a density of 2.86 pounds per cubic foot, which was equivalent in weight to a commercial cotton batting of 5.54 ounces per square foot. When this product was subjected to a cyclic compressive loading test to determine the percent set, taken after 50 loadings at 1 pound per square inch, it had an immediate set of 11%, under conditions of 60% relative humidity, and an immediate set of 19%, under conditions of 100% relative humidity. One hour later this sample had a set of 8% or less, under both 60 and 100% humidity conditions. In contrast, an untreated cotton batting of comparable weight subjected to the same test had an immediate set of 41.8% under the conditions of 60% RH. (relative humidity) and 45.5% under 100% RH. After one hour the untreated cotton had a set of 31% under the 60% RH. conditions and 42% under the 100% RH. Similar disparity in behavior was shown in energy absorption and stability to 15,000 cycles of loading.

EXAMPLE 2 Using the same type feed as above and forming a web in a similar manner spraying was then carried out using a spray media containing 17.7% solids. The solids consisted of 58% urea-formaldehyde and 42% vinyl acetate by weight. The resulting sprayed webs were then collected on a reel with condensing being carried out on a web for web basis until 30 webs had been collected. The partially formed batts were removed from the reel by slitting, and then placed in frames spaced in., 1 in., 1% in., and 1 /2 in. apart for drying and curing. The resulting products had densities of 3.22, 2.96, 2.91, and 2.58 pounds per cubic foot, respectively, and thicknesses of 1.14 in., 1.30 in., 1.38 in., and 1.45 in., respectively. After 50 cycles of compressional loading and unloading to 1 pound per square inch, these products had immediate sets of 17.3, 13.2, 17.1, and 18.9% when the test was run at 60% R.H., and after one hour of recovery had sets of 8.7, 4.6, 5.7, and 12.2%. When this test was run at 100% R.H., the samples had immediate sets of 20.0, 30.4, 28.5, and 32.5%, and after one hour recovery they had sets of 12.6, 22.7, 20.0, and 21.6% respectively.

8 EXAMPLE 3 Three companion batts were made from a comparable feed to that described in Example 1, using a spray media containing 10% solids, which was made up of methylated methylol melamine and 20% vinyl acrylic copolymer. The batts contained 20, 30, and 40 webs. The still spray damp webs were condensed by compression rolling to a thickness of about A of an inch. They were then placed in frames spaced 1%. in. apart, and dried and cured. The finished batts had densities of 1.48, 1.71, and 1.93 pounds per cubic foot, respectively. When tested by the cyclic loading and unloading compression test they had immediate set values of 29.0, 26.3, and 26.3% under conditions of 60% R.H., and 30 minutes later the respective values were 22.9, 18.8, and 21.5%. The values at RH. were 37.9, 41.0, and 37.2%, and these set values 30 minutes later were respectively 27.4, 34.7, and 33.7%. These values were significantly better than those achieved by comparable untreated cotton batts.

EXAMPLE 4 Using a comparable feed to that described for Example 1, and spraying the web from the card with a media containing 18.7% solids, which consisted of 53% ureaformaldehyde, 36% vinyl acrylic copolymer, and 11% styrene-butadiene copolymer batts consisting of 30 webs were built upon the reel device and condensed on a web 'for web basis. The partially formed batts were placed in frames spaced in. and 1 in. apart. Following the drying and curing, these batts had densities of 3.46 and 2.94 pounds per cubic foot, respectively. When subjected to the cyclic compressional loading and unloading compression test at 60% R.H., these samples had set values of 9.4 and 12.9% immediately upon completion of the test, and 10 minutes later they had s t values of 2.7 and 8.1%, respectively. Under conditions of 100% RH. the same samples showed sets of 15.2 and 21.0%, and after 30 minutes recovery these values changed to 8.3 and 16.2%, respectively. (Note: This is a significant improvement in performance at high relative humidity.) These samples were compressed to /2 their original height, and subjected to a temperature of 158 F. for 22 hours, and the set taken measured after /2 hour of recovery at ambient laboratory conditions of 60% RH. and 7073 F. temperature. The set in this case was 18.9%, and 21.0%, which changed to 8.1 and 9.8%, respectively, after 5 /2 hours.

EXAMPLE 5 The feed for this experiment consisted of 42% textile waste of various grades including picker, sweeps, and fly, and 58% first cut linters all of which had been scoured and mercerized. A portion of this material was formed into a web, and sprayed with a suspension of 15% solids, which consisted of 50% urea-formaldehyde and 50% vinyl acetate copolymer, and another portion sprayed with a combination solution suspension consisting of 20% solids made up of 70% dimethylol ethyl carbamate and 30% vinyl acetate copolymer. The product batts were obtained by lapping the web back and forth in a semi-conventional manner by hand until 30 webs had been built up in each case. The partially formed batts were condensed by rolling to a thickness of about 1 inch, and then placed in frames spaced 1% in. for drying and curing. When tested by the cyclic loading and unloading compression test these samples showed sets of 30.3% and 16.7% immediately upon completion of the test at 60% R.H., and 30 minutes later had set values of 10.5 and 8.3%, respectively. When the same test was carried out at 100% R.H., the samples had values of 32.4 and 23.0% immediately, and 28.8 and 19.2% respective values onehalf hour later.

9 EXAMPLE 6 Scoured but not mercerized raw stock similar to that described for Example was treated with formaldehyde by the wet treatment known as form W formaldehyde process,

containing 15% solids, 50% of which was urea-formaldehyde, and the other 50% vinyl acetate copolymer. Another portion of the web was sprayed with a set values of 19.4 and 21.6%, after the completion of the test, and 14.9% one half-hour later, R.H. The set values at 100% 21.6%

later.

respectively, immediately and values of set of 9.7% under conditions of 60% RH. were at 29.0 and immediately, and 17.7 and 14.9% one-half hour EXAMPLE 7 The feed material for this example consisted of 60% first cut linters and 40% textile wastes of various grades similar to those in Example 1. One batt was made by spraying the web with a suspension of a vinyl acrylic copolymer at a 20% solids content, and one batt was made by spraying the web with a solution containing methylated methylol melamine at 20% solids content. After spraying, forming, and condensing the batts were placed in frames 1% inch during curing, a batt was produced which had a density of 1.71 pounds per cubic foot. This batt was subjected to 15,000 cycles of loading and unloading at the rate of 132 cycles per minute, and approximately 1 pound per square inch. The immediate set for this sample was 11.2%, and after recovering for 24 hours at 60% RH. and 70 F. the sample had a set value of 3.3%. An

' untreated control cotton to Example 1, it can be batting of comparable weight showed an immediate set of 40.6%, and after 24 hours the set was 29.7%. The experimental sample showed no tendency to compact under these conditions while compaction was evident in the untreated cotton batting.

EXAMPLE 9 Using a feed material similar to Example 1, and spraying the web as discharged from the card to a wet pickup of 130%, with a solution containing 10% solids, which was made up of 40% methylated methylol melamine and 60% vinyl acrylic copoly-mer by weight, a hand forming and had a density of 1.42 pounds was equivalent to a commercial after 50 of 1 pound per square inch at 60% R.H., and 46.4% at 100% RH. After 30 minutes of recovery the sample had a set value of 19.6% at 60% R.H., and 39.3% at 100% RH. The product required a held compressed to /2 its normal thickness at a tempera ture of 158 F. for 22 hours and then allowed to freely recover for 30 minutes at ambient room conditions the batt showed a set of 21.4%. This performance is better than that of untreated cotton batting as can be seen by referring to the data given in Example 1.

EXAMPLE 10 and 31.6%, respectively. Thirty minutes later these values were 10% and 25%, respectively. When held compressed to /2 its normal thickness at 158 F. for 22 hours, and then allowed to recover for 30 minutes at ambient room conditions, this sample had a set of 21.2%. By referring seen that these samples performed better than untreated cotton batting.

EXAMPLE 11 was methylol melamine and 60% vinyl acrylic copolymer followed by hand layup, a batt consisting of 30 webs was produced. This batt was placed in frames spaced 1% inches apart and dried at 200 F. for minutes and then cured at 300 F. for 30 minutes. The resulting cured batt had a resin add-on (excluding latex) a density of 1.98 pounds per cubic foot and by the cyclic immediately upon completion of and a set of 46.2% under conditions of relative humidity. Ten minutes later the values Were and 37.2% respectively. When subjected to a 11 compression to /2 its original thickness at a temperature of 158 F. for 22 hours and allowed to recover for 30 minutes at ambient room temperature, this material had a set of 24.3%.

EXAMPLE 12 Using a feed material similar to that used for Example 1 and spraying the web as it is discharged from the garnett with a solution containing solids, all of which was in the form of methylated methylol melamine, a product was produced which had a resin add-on of 24.2%. The product required a load of 5.72 pounds on a compression foot of 50 square inches to reduce the thickness of a 100 square inch sample to 75% of its original thickness. This product had a textile breaking strength of 24.5 lbs. in the direction of the fiber lay compared with a textile breaking strength of 5.20 pounds for untreated cotton batting sample of comparable weight. Similar differences were shown when the treated sample was tested for breaking strength in the direction transverse to the fiber lay and compared with the breaking strength of comparable weight untreated batting.

EXAMPLE 13 Using a feed material similar to that shown for Example 1 and spraying the web as it is discharged from the 'garnett with a solution containing 15% solids of which 60% was methylated methylol melamine and 40% was vinyl acrylic copolymer followed by hand layup, a batt was produced having 40 webs. This product had a resin add-on of 10.2% (excluding latex) after drying and curing in frames spaced 1% inches apart. The density was 1.80 pounds per cubic foot, and on a weight basis was equivalent to untreated batting of 3.68 ounces per square foot. When tested for compression set under conditions of 60 and 100% relative humidity, this sample had set values of 24.4 and 41% immediately, and values of 20.5% and 37.2% after 4 minutes. This product required a load of 7.48 pounds on a 50 square inch foot to reduce the thickness of the sample by When compressed to /2 its origintal thickness and held at 158 F. for 22 hours, this sample demonstrated a set due to heat under load of 25.5% permitted to recover for /2 hour under room conditions without load. This sample showed a textile breaking strength in the direction of fiber lay of 44 pounds compared with 5.2 pounds for untreated cotton batting.

EXAMPLE 14 Using a raw stock feed consisting of 60% first out linters and 40% textile waste, which was made up of 10% willowed picker, 10% willowed sweeps, and 20% willowed fly, a web was made with a sample card equipped with garnett type wire. The web was sprayed while on the apron of the card with a chemical formulation consisting of 18.3% solids. The solids consisted of 52.1% by weight of methylated methylol melamine and 47.9% by weight of vinyl acrylic copolymer. The sprayed Web had a wet add-on of about 100% by Weight of the cotton fed. This spray damp cotton batting was collected on a reel type device (item 11, FIGURE 1B), until a total of webs had been built up. The spray damp material was then removed from the reel and placed in a pair of molds made of expanded metal to simulate the contours of the arm of an upholstered sofa (FIGURES 4A, B, C).

Note.-The use of expanded metal for mold parts is in no way critical to this invention.

The male and female pieces of the molds were then spaced so that the finished molded cotton batting product would have a density to approximately 2.5 pounds per cubic foot. The spray damp cotton in the confining mold Was then placed in a cabinet type oven and submitted to the drying step which consisted of heating the material and mold for 2 hours at 200 F., followed by a 20 minute cure at 300 F.

The contoured fibrous cotton batt produced here was removed from the mold once it cooled to near room temperature, and upon close scrutiny and evaluation was found to have faithfully reproduced the contours of the mold, and exhibited a tensile strength in excess of 25 pounds in the direction of the fiber lay, and 15 pounds in the direction transverse to the fiber lay. The resiliency of the contoured fibrous cotton batt produced here was such that it returned to its origintal shape and position after a series of standard compressive loadings. Untreated cotton batting material which was submitted as control did not demonstrate sufficient integrity to hold a shape unless it was draped over the arm of a piece of furniture.

EXAMPLE 15 Using a feed of the type stated in Example 14 and a chemical formulation of the same general composition a spray damp batting having about an 85% wet add-on, based on the dry cotton fed to the sample card, was produced. This spray damp batting was placed in a mold which was specifically designed to simulate an automobile bucket seat (FIGURES 5A, B, C), the two halves of the confining mold being spaced so that a product having a density of 2.4 pounds per cubic foot, was produced, the impregnated spray damp material being dried at 200 F. for 2 hours, and cured at 300 F. for minutes. The drying and curing of this experimental product were under investigation, and known to be excessive. Commercially, the drying time should be about from 2 to 30 minutes at the stated temperature, while the curing time should be about from 2 to 30 minutes at the stated temperatures, depending upon the thickness and density of the finished product.

The contoured fibrous cotton batt produced here was removed from the mold once it cooled to near room temperature, and upon close scrutiny and evaluation was found to have reproduced faithfully all of the concave and convex curvatures. This configuration was retained by the product after being submitted to severe handling, which consisted of twisting, pulling, and tearing attempts. The tensile strength of the product was in excess of 20 pounds in either the machine direction or the transverse direction. The resiliency of this batt with curved configuration was comparable to that of a pad with the fiat configuration produced by the process of the aforesaid Patent No. 3,181,225. The recovery evaluations were determined from deformation loading cycles at 1.0 pound per square inch, and 85% recovery was obtained within 4 minutes when the relative humidity was about -65%, and recovery was obtained within the same period of time when the relative humidity was The bonding and shape reproducing characteristics of the resins and latexes used in the product reinforce each other in reducing the powdering or dusting out of short fibers from the product when it is in use.

EXAMPLE 16 Using a feed of the type stated in Example 14 and a chemical formulation consisting of 20% solids to spray the cotton fibers while these were openly arrayed on the apron of the card, a product having a varying density at chosen locations was produced.

The spray solution was made up of 50% by weight of methylated methylol melamine, and 50% by weight of solids of vinyl acetate copolymer. This solution was sprayed onto the raw stock feed and a spray damp wet add-on was obtained. This spray damp cotton batt which was made up of 20 webs of sprayed fibers was placed into the female portion of the expanded metal molds shown in FIGURES 4 and 5. The halves of the confining molds were then adjusted so that the density of the product would vary from point to point, with the densest portion in mold A (FIGURES 4A, B, and C) at the transition from fiat to curved surface, and in mold B (FIGURES 5A, B, and C) with points of highest den- 3,350,486 sity occurring in the sharp short curved surface and at the (d) placing the thus-produced batt within a confining ba e of the large scooped shaped section. The samples mold designed to impart to the finished batt a con- Were dried in a cabinet oven for 2 hours at 200 F. and figuration of a selected contour and the cavity of cured at 320 F. for 30 minutes. which is nonuniform with respect to thickness;

The fibrous cotton batt wherein selected portions of (e) applying pressure to the batt While in the mold; the batt exhibit varying degrees of resilience through (f) drying the batt 1n the mold for about from 5 to 30 varying degrees of fibrous compaction was removed from minutes at about from 180 to 220 F.; and the mold once it cooled to near room temperature, and (g) curing the dried batt in the mold for about from 2 upon close scrutiny and evaluation were found to demonto 15 minutes at about from 300 to 320 F. to prostrate a density gradient throughout the product, the duce .a batt with varying degrees of fibrous comgreatest density for mold A (FIGURES 4A, B, and C) paction. being at the region where th re is transition from fiat to 3. A method of producing a contoured fibrous cellulosic curved; and in the case of mold B (FIGURES 5A, B, batt having dimensional stability, coherence, and reand C) with the greatest densities occurring at the neck, siliency, comprising or small curved section, and again at the base of the (a) forming a continuous Web of opened textile fibers large scooped section. This is demonstrated more clearly selected from the group consisting of cotton fibers, in FIGURE 6 Where greatest density occurred at the chemically modified cellulosic fibers, and blends thinnest portions of the product. thereof;

These products show excellent resiliency. Eflicient and (b) spraying the web to a wet add-on of about from rapid recovery from deformation loading was observed 50% to 150% by weight, based on the weight of the in the evaluation of the products produced by this procunsprayed web, with .a composition containing a ess. The shape recovering characteristics were considered thermosetting cellulose reactive crosslinking resin and durable through rough handling, and the product had a thermoplastic film-forming latex to a resin add-on tensile strengths in excess of 20 pounds in the direction of about from 3.76% to 24.2% by Weight, based on of the fiber lay, and 20 pounds in the transverse direction. the weight of the unsprayed web, of said thermo- We claim: setting cellulose reactive crosslinking resin;

1. A method of producing a contoured fibrous cellu- (c) lapping the thus-sprayed web to obtain a multilosic batt having dimensional stability, coherence, and plicity of layers and compressing said layers to proresiliency, comprising duce a spray damp batt having a degree of damp- (a) forming a continuous web of opened textile fibers ness amounting to at least about 50% by Weight,

selected from the group consisting of cotton fibers, ba ed on the weight of the unsprayed Web; chemically modified cellulosic fibers, and blends (d) placing the thus-produced spray damp batt within thereof; .a confining mold designed to impart to the finished (b) spraying the web to a wet add-on of about from batt a configuration of a selected contour;

50% to 150% by weight, based on the weight of the (e) drying the batt in the mold for about from 5 to 30 unsprayed web, with a composition containing a therminutes at about from 18 to 220 F.; and mosetting cellulose reactive crosslinking resin to a (f) curing the dried batt in the mold for about from resin add-on of about from 3.76% to 24.2% by 2 to 30 minutes at about from 300 to 320 F. weight, based on the Weight of the unsprayed Web, 4. Amethod of producing a contoured fibrous cellulosic of said thermosetting cellulose reactive crosslinking batt having dimensional stability and coherence, and havresin; ing, in addition, selected portions which exhibit varying (c) lapping the thus-sprayed web to obtain a multidegres of resiliency resulting from preselected varying deplicity of layers and compressing said layers to progrees of compaction applied thereto, comprising duce a spray damp batt having a degree of damp- (a) forming a continuous Web of opened textile fibers ness amounting to at least about 50% by Weig t, selected from the group consisting of cotton fibers, based on the weight of the unsprayed web; chemically modified cellulosic fibers, and blends (d) placing the thus-produced spray damp batt within thereof;

a confining mold designed to impart to the finished (b) spraying the web to a w t addf b t f batt a configuration of a selected n to 150% by Weight, based on the weight of the (e) drying the batt in the mold for about from 5 to 50 unsprayed web, with a composition containing a 0 minutes at about from 180 to 220 F.; and thermosetting cellulose reactive crosslinking resin and (f) curing the dried batt in the mold for about from a thermoplastic film-forming latex to a resin add-on 2 to 30 minutes at about from 300 to 320 F. of about from 3.76% to 24.2% by Weight, based on 2 Amethod of producinga contoured fibrous cellulos1c the weight of th unsprayed w b, f id th batt having dimensional stability and coherence, and havsetting celluose reactive crosshnking resin ing, in addition, selected portions which exhibit varylng (c) lapping the thus-sprayed Web to obtain a mu1t1- degrees of resiliency resulting from preselected varying plrcity of layers and compressing said layers to prodegrees of compaction applied thereto, oomprrsmg duce a spray damp batt having a degree of dampness (a) forming a continuous Web of opened textile fibers amounting to at least .about 50% by Weight, based on selected from the group consisting of cotton fibers, 0 the weight of the unsprayed Web; chemically modified cellulosic fibers, and blends (d) placing the thus-produced batt within a confining thereof; mold designed to impart to the finished batt a con- (b) spraying the Web to a Wet add-on of about from figuration of a selected contour and the cavity of 50% to by weight, based on the weight of the which is nonuniform with respect to thickness; unsprayed web, with a composition containing a 5 (e) applying pressure to the batt while in the mold; thermosetting cellulose reactive crosslinking resin to (f) drying the batt 1n the mold for about from 5 to 30 a resin add-on of about from 3 76% to 24.2% b minutes at about from to 220 and weight, based on the weight of the unsprayed web (g) curing the dried batt 11! the mold for about from 2 of said thermosetting cellulose reactive crosslinking to 15 minutes at about from 300 to 320 F. to proresin; 7 duce a batt with varying degrees of fibrous compac- (c) lapping the thus-sprayed web to obtain a multition.

plicity of layers and oompressing said layers to pro- 5. The process of claim 1 wherein the fibers are cotton duce a spray damp batt having a degrees of dampness fibers and the thermosetting resin is methylated methylol amounting to at least about 50% by weight, based on melamine.

the Weight of the unsprayed web; 75 6. The process of claim 3 wherein the thermosetting resin is selected from the group consisting of methylated methylol melamine, urea-formaldehyde, dimethylol ethyl carbarnate, and tris(1-aziridinyl)phosphine oxide and the thermoplastic film-forming latex is selected from the group consisting of vinyl acrylic copolymer, vinyl acetate copolymer, styrene-butadiene copolymer, and .a mixture of said vinyl acrylic copolymer and said styrenebutadiene copolymer.

7. The process of claim 3 wherein the fibers are cotton fibers, and the spray composition contains about from 1 to 4 parts by weight of methylated methylol melamine as the thermosetting resin and about 1 part by weight of vinyl acrylic copolymer as the thermoplastic latex.

8. The process of claim 3 wherein the fibers are cotton fibers, and the spray composition contains approximately equal parts by weight of urea-formaldehyde as the thermosetting resin and vinyl acetate copolymer as the thermoplastic latex.

9. The process of claim 3 wherein the fibers are cotton fibers, and the spray composition contains about 1 part by weight of urea-formaldehyde as the thermosetting resin and, as the thermoplastic latex, about 1 part by weight of a copolymer mixture of vinyl acrylic copolymer and styrene-butadiene copolymer, the two copolymers being 16' of 3 parts by weight of the vinyl part by weight of the styrenein the approximate ratio acrylic copolymer to 1 butadiene copolymer.

10. The process of claim 3 wherein the fibers are cotton fibers that have ben chemically modified by the form W formaldehyde treatment, and the spray composition contains about 7 parts by Weight of dimethylol ethyl carbamate as the thermosetting resin and about 3 parts by weight of vinyl acetate copolymer as the thermoplastic latex.

11. The process of claim 3 wherein the fibers are cotton fibers that have been mercerized, and the spray composition contains approximately equal parts by weight of ureaformaldehyde as the thermosetting resin and vinyl acetate copolymer as the thermoplastic latex.

References Cited UNITED STATES PATENTS 3/1949 Bowes ROBERT F. WHITE, Primary Examiner. J. R. HALL, Assistant Examiner. 

1. A METHOD OF PRODUCING A CONTOURED FIBROUS CELLULOSIC BATT HAVING DIMENSIONAL STABILITY, COHERENCE, AND RESILIENCY, COMPRISING (A) FORMING A CONTINUOUS WEB OF OPENED TEXTILE FIBERS SELECTED FROM THE GROUP CONSISTING OF COTTON FIBERS, CHEMICALLY MODIFIED CELLULOSIC FIBERS, AND BLENDS THEREOF; (B) SPRAYING THE WEB TO A WET ADD-ON FO ABOUT FROM 50% TO 150% BY WEIGHT, BASED ON THE WEIGHT OF THE UNSPRAYED WEB, WITH A COMPOSITION CONTAINING A THERMOSETTING CELLULOSE REACTIVE CROSSLINKING RESIN TO A RESIN ADD-ON OF ABOUT FROM 3.76% TO 24.2% BY WEIGHT, BASED ON THE WEIGHT OF THE UNSPRAYED WEB, OF SAID THERMOSETTING CELLULOSE REACTIVE CROSSLINKING RESIN; (C) LAPPING THE THUS-SPRAYED WEB TO OBTAIN A MULTIPLICITY OF LAYERS AND COMPRESSING SAID LAYERS TO PRODUCE A SPRAY DAMP BATT HAVING A DEGREE OF DAMPNESS AMOUNTING TO AT LEAST ABOUT 50% BY WEIGHT, BASED ON THE WEIGHT OF THE UNSPRAYED WEB; (D) PLACING THE THUS-PRODUCED SPRAY DAMP BATT WITHIN A CONFINING MOLD DESIGNED TO IMPART TO THE FINISHED BATT A CONFIGURATION OF A SELECTED CONTOUR; (E) DRYING THE BATT IN THE MOLD FOR ABOUT FROM 5 TO 30 MINUTES AT ABOUT FROM 180* TO 220*F.; AND (F) CURING THE DRIED BATT IN THE MOLD FOR ABOUT FROM 2 TO 30 MINUTES AT ABOUT FROM 300* TO 320*F. 